CN109071302B - Cold forming of complex curved glass products - Google Patents

The principles and embodiments of the present disclosure generally relate to complexly-curved glass articles, such as complexly-curved glass articles having a first bending region with a first set of curve segments and a second bending region with a second set of curve segments, wherein the first and second curve segments are independent, non-parallel, and do not intersect, and methods of cold forming complexly-curved glass articles.

Cold forming of complexly curved glass articles

Cross Reference to Related Applications

The present application claims priority rights to united states provisional application serial No. 62/328,165 filed 2016, 4, 27 and united states provisional application serial No. 62/305,795 filed 2016, 3, 9, 3, 119, the contents of each provisional application being based on and incorporated by reference herein in their entirety.

Technical Field

The principles and embodiments of the present disclosure generally relate to complexly curved glass articles and methods of cold forming complexly curved glass articles.

Background

Vehicle manufacturers are building interior trim that better connects, protects, and safely informs today's drivers and passengers. As the industry moves toward autopilot, there is a need to build large format displays that are attractive. In some OEM new models, a trend has emerged towards larger displays incorporating touch functionality. However, most of these displays consist of a two-dimensional plastic cover lens.

Due to these emerging trends in the automotive interior industry and related industries, there is a need to develop low cost techniques to produce three-dimensional transparent surfaces. A further interest is to develop automotive interior parts that include bending in different directions while maintaining complete independence between bends.

One of the methods that may be used to fabricate three-dimensional automotive interior display surfaces is to use plastic for fabrication. Although plastic materials can be shaped in three-dimensional molds including multi-axis bending, glass is advantageous over plastic in many respects. In particular, plastic materials are prone to permanent damage during blunt object impact, general wear and UV exposure.

Three-dimensional glass surfaces are often formed by a hot forming process. The process is also capable of forming three-dimensional automotive interior displays that are curved in more than one direction. Such glass bending methods involve heating the glass sheet and shaping the glass sheet while the glass sheet is still in a high temperature state at or near the softening temperature of the glass.

However, the thermoforming process is energy intensive due to the high temperatures involved, and such processes add significant cost to the product. In addition, it is desirable to provide an antireflective coating or other coating on the interior display surface of an automobile. Providing the coating uniformly over a three-dimensional surface using vapor deposition techniques is extremely difficult and also increases process costs.

The cold forming process, which may also be referred to as cold bending, has been used to solve some of the problems described above. However, cold bending is limited to bending or curvature along one axis. The construction of reciprocal curved glass involving opposing curvatures at one point is strictly limited to large bending radii (1m or greater) and is used primarily in building or construction applications. The cold bending process induces permanent strains, resulting in the formation of permanent stresses in the glass sheet.

Accordingly, there is a need for new complex curved glass articles and methods of making the same that can be used, for example, in automotive interiors and other applications.

Disclosure of Invention

A solution to at least one of the above problems involves a glass article having a complex curved shape formed by cold forming. One aspect of the present disclosure relates to complexly curved glass articles that have been formed by a cold forming process. A second aspect of the present disclosure is directed to a method of forming a complexly curved glass article using a cold forming process. According to one or more embodiments, the cold forming process is a cold bending process using a preform having a first bending region with a first set of curve segments and a second bending region with a second set of curve segments, wherein the first and second curve segments are independent, non-parallel, and non-intersecting. In various embodiments, the glass article is a laminate comprising at least two substrates, and the cold forming process is conducted at a temperature below the glass transition temperature of any one of the substrates used to form the laminate. Thus, the methods described herein do not require heating to a temperature at or near the glass transition temperature of the glass, thereby reducing manufacturing time and cost by avoiding heating operations on the glass substrate.

Another aspect of the present disclosure relates to a vehicle interior trim component comprising a complexly curved glass article. Another aspect of the present disclosure relates to a vehicle comprising a vehicle interior trim component.

Various embodiments are listed below. It is to be understood that the embodiments listed below may be combined not only as listed below, but also in other suitable combinations in accordance with the scope of the present disclosure.

Drawings

Other features of embodiments of the present disclosure, their nature and various advantages will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are also illustrative of the best mode contemplated by the applicant and in which like reference characters designate like parts throughout the drawings, wherein:

FIG. 1A is a perspective view of a preform and a glass article having a plurality of bending regions;

FIG. 1B is another perspective view of the preform and glass article shown in FIG. 1A having multiple bending regions;

FIG. 1C is a front view of the preform and glass article shown in FIG. 1A having multiple bending regions;

FIG. 1D is a top view of the preform and glass article shown in FIG. 1A having multiple bending regions;

FIG. 1E is a side view of the preform and glass article shown in FIG. 1A having multiple bending regions;

FIG. 1F is a rear perspective view of the preform and glass article shown in FIG. 1A having multiple bending regions;

FIG. 1G is a rear view of the preform and glass article shown in FIG. 1A having multiple bending regions;

FIG. 2A is a perspective view of another exemplary embodiment of a preform and a glass article having a plurality of bending regions;

FIG. 2B is a front view of the preform and glass article shown in FIG. 2A having multiple bending regions;

FIG. 2C is a side view of the preform and glass article shown in FIG. 2A having multiple bending regions;

FIG. 2D is a top perspective view of the preform and glass article shown in FIG. 2A having multiple bending regions; and

fig. 3A-3F illustrate various exemplary embodiments of a glass sheet prior to bending along different bending axes to provide a plurality of bending regions.

Detailed Description

Before describing several exemplary embodiments of the present disclosure, it is to be understood that the present disclosure is not limited to the details of construction or method steps set forth in the following description. The description of the present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

Reference throughout this specification to "one embodiment," certain embodiments, "" various embodiments, "one or more embodiments," or "an embodiment" means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases "in one or more embodiments," "in certain embodiments," "in various embodiments," "in one embodiment," or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment of the present disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

It has been discovered that cold forming processes (e.g., cold bending) can be used to produce complex curved glass articles by using a preform configuration in which one bend in a first direction is independent of a second bend in a second direction. The cold bends can be single or double curvature throughout. In one or more embodiments, the cold bend is a single curvature bend and does not have any cross curvature.

As used herein, "cold forming" refers to a process of shaping glass to have a curved or three-dimensional shape at a temperature below the glass transition temperature of the glass. Thus, according to one or more embodiments, the temperature is at least 200 ℃ lower than the glass transition temperature of the glass in the cold forming process. As will be described herein, a glass article in the present disclosure refers to a glass sheet that has been shaped to have a plurality of bending regions. In one or more embodiments, the glass article comprises a glass sheet that is subjected to or subjected to cold forming. The cold-formed glass sheet includes a first major surface comprising a first compressive stress and an opposing second major surface comprising a second compressive stress, wherein the first major surface is greater than the second compressive stress.

As used herein, a "single-curvature" bend is a bend that is made at least in a part-cylindrical shape having a single radius of curvature. The axis passing through the center of the cylindrical curve and perpendicular to the radius of curvature is designated herein as the "bending axis". A line segment located on the surface of the curved region of the article and parallel to the axis of curvature is designated herein as a "curved line segment". Since the bending line segments are parallel to the associated bending axis, each bending zone having a parallel or non-parallel bending axis will have a parallel or non-parallel bending line segment, respectively.

As used herein, a "double curvature" or "cross curvature" curvature results from two interacting single curvatures having overlapping axes of curvature, where each single curvature has its own axis of curvature and radius of curvature. Such configurations include co-curved and counter-curved configurations. In a homodromous configuration, all normal cross-sections of the curved region are concave or convex, such as a shell or dome configuration. In a reciprocal curved surface configuration, some normal cross-sections of the curved region will have a convex shape while other normal cross-sections will have a concave shape, such as a saddle-shaped configuration. The curved line segments of articles with double curvature will bend due to the interaction of the two curvatures. Thus, the two interacting curved line segments of curvature in the double curvature are related rather than independent.

As used herein, "bend region" refers to a portion of an article that is bent in one or more directions. The curved region has a non-zero curvature throughout the region. The curved region may have a single curvature or a double curvature. In one or more embodiments, the curved region has a single curvature and does not have any cross curvature. One curved region may abut another curved region or may abut a flat region.

As used herein, "flat region" refers to a portion of an article having substantially zero curvature or having zero curvature. As used herein, "substantially zero curvature" means a radius of curvature greater than about 1 m. The flat region may be located between two or more curved regions. In one or more embodiments, the minimum distance between two non-adjacent curved regions is at least 10 millimeters, and thus, the flat region extends a distance of at least 10 millimeters. Exemplary flat regions may be extended by distances encompassing the following values or ranges defined by these values: 10. 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, or 950 millimeters, or 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.5, 3, 3.5, 4, 4.5, or 5 meters.

Fig. 3A-3F illustrate various exemplary embodiments of a glass sheet prior to bending along different bending axes to provide a plurality of bending regions. In each of fig. 3A-F, the dashed lines represent the bending axes, while the arrows represent the bending directions. As can be seen in fig. 3A, the glass sheet can be bent about two non-parallel bending axes of a substrate having two portions that provide an L-shaped sheet. As can be seen in fig. 3B, the glass sheet can be bent around two parallel bending axes on a first portion of the substrate and a third bending axis in a second portion of the substrate that is not parallel to the two first axes, the first and second portions providing a T-shaped substrate. As can be seen in fig. 3C, the glass sheet can be bent about two parallel bending axes in one portion, and another bending axis in a second portion and two parallel bending axes in a third portion, the first portion, the second portion, and the third portion providing a substantially I-shaped substrate. In fig. 3C, the bending axis in the second portion is not parallel to the bending axis in the first portion or the second portion. As can be seen in fig. 3D, the glass sheet can be bent about two parallel bending axes and a third bending axis that is not parallel to the two first axes on the first and second portions of the substrate, thereby providing an asymmetric T-shape. In addition, fig. 3D shows that the glass sheet need not be symmetrical before bending. As can be seen in fig. 3E, the glass sheet can be bent around two parallel bending axes in a first portion of the substrate and a third bending axis in a second portion of the substrate that is not parallel to the two first axes, the first and second portions providing a T-shaped substrate. As can be seen in fig. 3F, the glass sheet can be bent about three non-parallel bending axes. It should be understood that the configurations shown in fig. 3A-3F are merely exemplary and not limiting, and that the scope of the present disclosure includes any substrate having two portions with multiple bending regions.

Accordingly, one aspect of the present disclosure is directed to a glass article comprising a cold-formed, complexly-curved, continuous glass sheet having a first curve in a first portion of the glass sheet defining a first bending region and having a first set of curve segments and a second curve in a second portion of the glass sheet defining a second bending region and having a second set of curve segments, wherein the first curve segments and the second curve segments are independent, non-parallel, and do not intersect.

In one or more embodiments, the glass sheet has a thickness of 7 millimeters or less, for example, in a range from 25 micrometers to 5 millimeters. Exemplary thicknesses of the glass sheet include the following values or ranges defined by these values: 25. 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, or 950 micrometers, or 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.5, 3, 3.5, 4, 4.5, or 5 millimeters.

In one or more embodiments, the one or more bends have a radius of curvature greater than 20 mm, for example in the range of greater than 25 mm to less than 5 m. Exemplary bend radii include the following values or ranges defined by these values: 25. 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, or 950 millimeters, or 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.5, 3, 3.5, 4, 4.5, or 5 meters. Each bend may have the same or different radius of curvature as the other bend.

In one or more embodiments, the glass article has a first bending stress magnitude at the first bending region, a second bending stress magnitude at the second bending region, and a flat region stress magnitude, and the flat region stress magnitude differs from the first bending stress magnitude and the second bending stress magnitude by at least 1 MPa. Exemplary stress magnitude differences between each curved region and the flat region include the following values or ranges defined by these values: 1.2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 40, 50, 60, 70, 80, 90 or 100 MPa. The difference in stress magnitude between the respective curved and flat regions may be the same or different for each bend.

In one or more embodiments, the glass article may include a strengthened glass sheet (the strengthening being performed prior to forming the glass sheet into embodiments of the glass article described herein). For example, the glass sheet may be heat strengthened, tempered glass, chemically strengthened, or strengthened by a combination of these strengthening. In one or more embodiments, the strengthened glass sheet has a Compressive Stress (CS) layer that extends from a surface of the glass sheet to a depth of layer of compressive stress (DOL).

As used herein, "heat-strengthened" refers to heat-treating an article to improve the strength of the article, and includes both tempered and heat-strengthened (heat-strengthened) articles, such as tempered glass and heat-strengthened glass. Tempering glass involves an accelerated cooling process that results in higher surface and/or edge compression in the glass. Factors that affect the degree of surface compression include air quench temperature, volume, and other variables that result in a surface compression of at least 10,000 pounds per square inch (psi). The heat strengthened glass is produced by slower cooling than tempered glass, which results in lower compressive strength at the surface, and the strength of the heat strengthened glass is approximately twice that of annealed or untreated glass.

In a chemically strengthened glass sheet, the replacement of smaller ions with larger ions at a temperature lower than the temperature at which the glass network can relax can produce an ion distribution on the glass surface, which results in the formation of a stress distribution. The larger volume of the incoming ions creates CS extending from the surface of the glass and creates tension in the center of the glass (central tension, or CT). T is

In a strengthened glass sheet, the depth of compressive stress is related to the central tension by the following approximate relationship (equation 1):

wherein the thickness is a total thickness of the strengthened glass sheet and the depth of compressive layer (DOL) is a depth of compressive stress. Unless otherwise indicated, the central tension CT and the compressive stress CS are expressed herein in megapascals (MPa), while the thickness and depth of layer DOL are expressed in millimeters or micrometers.

In one or more embodiments, the surface CS of the strengthened glass sheet can be 300MPa or greater, such as 400MPa or greater, 450MPa or greater, 500MPa or greater, 550MPa or greater, 600MPa or greater, 650MPa or greater, 700MPa or greater, 750MPa or greater, or 800MPa or greater. The strengthened glass sheet can have a depth of compressive layer of 15 microns or more, 20 microns or more (e.g., 25, 30, 35, 40, 45, 50 microns or more), and/or a central tension of 10MPa or more, 20MPa or more, 30MPa or more, 40MPa or more (e.g., 42MPa, 45MPa, or 50MPa or more), but less than 100MPa (e.g., 95, 90, 85, 80, 75, 70, 65, 60, 55MPa or less). In one or more particular embodiments, the strengthened glass sheet has one or more of the following parameters: a surface compressive stress greater than 500MPa, a compressive depth of layer greater than 15 microns, and a central tension greater than 18 MPa.

The strengthened glass sheets described herein can be chemically strengthened by an ion exchange process. In an ion exchange process, ions at or near the surface of the glass sheet are exchanged with larger metal ions from the salt bath, typically by immersing the glass sheet in a molten salt bath for a predetermined period of time. In one embodiment, the temperature of the molten salt bath is from about 375 ℃ to about 450 ℃ and the predetermined time is from about 4 hours to about 8 hours. In one example, sodium ions in the glass sheet are replaced by potassium ions in a molten bath (e.g., a potassium nitrate salt bath), but other alkali metal ions with larger atomic radii (e.g., rubidium or cesium) may also replace smaller alkali metal ions in the glass. In another example, lithium ions in the glass sheet are replaced by potassium and/or sodium ions in a molten bath that may include potassium nitrate, sodium nitrate, or a combination thereof, although other alkali metal ions with larger atomic radii (e.g., rubidium or cesium) may also replace smaller alkali metal ions in the glass. According to particular embodiments, the smaller alkali metal ions in the glass sheet may be Ag⁺And (4) ion replacement. Similarly, other alkali metal salts, such as, but not limited to, sulfates, phosphates, halides, and the like, may be used in the ion exchange process.

In Chemically Strengthened substrates, the CS and DOL are determined by a Surface stress meter (FSM) using commercially available instruments, such as FSM-6000 manufactured by Luceo Co., Ltd., Tokyo, Japan, and the like, and methods for measuring CS and depth of layer are described in ASTM 1422C-99 entitled Standard Specification for Chemically Strengthened Flat Glass and ASTM1279(1979) Standard Test Method for nondestructive Photoelastic Measurement of Edge and Surface Stresses in Annealed, Heat Strengthened, and Fully Tempered Flat Glass (Standard Test Method for Non-Destructive optical elastic Measurement of Edge and Surface Stresses in Annealed, Heat Strengthened, and Fully Tempered Flat Glass), which is incorporated herein by reference in its entirety. Surface stress measurement relies on the accurate measurement of the Stress Optical Coefficient (SOC), which is related to the birefringence of the glass. SOC can in turn be determined using methods known in the art, such as the fiber and four-point bending Method, described in ASTM Standard C770-98(2008), entitled Standard Test Method for Glass Stress-Optical Coefficient determination (Standard Test Method for measuring Glass Stress-Optical Coefficient), and the large cylinder Method, which is incorporated herein by reference in its entirety.

The materials used for the glass article can be varied. The glass sheet used to form the glass article may be an amorphous article or a crystalline article. According to one or more embodiments, the amorphous glass sheet may be selected from the group consisting of soda lime glass, alkali aluminosilicate glass, alkali borosilicate glass, and alkali aluminoborosilicate glass. Examples of crystalline glass sheets may include glass ceramics, sapphire, or spinel. Examples of glass-ceramics include Li₂O-Al₂O₃-SiO₂System (i.e., LAS system) glass-ceramics; MgO-Al₂O₃-SiO₂System (i.e., MAS system) glass-ceramics; a glass-ceramic comprising a crystalline phase, the crystalline phase being any one or more of: mullite, spinel, alpha-quartz, beta-quartz solid solution, petalite, lithium disilicate, beta-spodumene, nepheline, and alumina.

Various different methods may be used to provide the glass sheet. For example, exemplary glass sheet forming methods include float glass processes and down-draw processes, such as fusion draw and slot draw. Glass sheets made by the float glass process can be characterized by smooth surfaces, and uniform thickness is produced by floating molten glass on a bed of molten metal (usually tin). In one exemplary process, molten glass is fed onto the surface of a bed of molten tin to form a floating glass ribbon. As the ribbon flows along the tin bath, the temperature gradually decreases until the ribbon solidifies into a solid glass sheet that can be lifted from the tin onto the rollers. Once out of the bath, the glass sheet may be further cooled and annealed to reduce internal stresses.

The downdraw process produces glass sheets having a uniform thickness, which have relatively pristine surfaces. Because the average flexural strength of the glass sheet is controlled by the amount and size of the surface flaws, the pristine surface that has the least contact has a higher initial strength. When the high-strength glass sheet is further strengthened (e.g., chemically strengthened), the resulting strength may be higher than that of a glass sheet whose surface has been polished and polished. The downdraw glass sheet may be drawn to a thickness of less than about 2 millimeters. In addition, the downdrawn glass sheet has a very flat, smooth surface that can be used for the final application of the glass sheet without the need for expensive grinding and polishing.

The fusion draw process uses, for example, a draw tank having a channel for receiving molten glass feedstock. The channel has a weir that opens at the top along the length of the channel on both sides of the channel. As the channel is filled with molten material, the molten glass overflows the weir. Under the action of gravity, the molten glass flows down from the outer surface of the draw tank as two flowing glass films. The outer surfaces of these drawn cans extend downwardly and inwardly so that they meet at the edge below the drawn can. The two flowing glass films meet at the edge to fuse and form a single flowing glass sheet. The fusion drawing method has the advantages that: because the two sheets of glass film that overflow the channel fuse together, neither outer surface of the resulting glass sheet is in contact with any part of the apparatus. Thus, the surface properties of the fusion drawn glass sheet are not affected by such contact.

The slot draw process is different from the fusion draw process. In the slot draw process, molten raw material glass is supplied to a draw tank. The bottom of the drawn can has an open slot with a nozzle extending the length of the slot. The molten glass flows through the slot/nozzle, is drawn downward in the form of a continuous sheet, and enters an annealing zone.

Exemplary compositions for glass sheets will now be described. An exemplary glass composition comprises SiO₂、B₂O₃And Na₂O, wherein (SiO)₂+B₂O₃) Not less than 66 mol% and Na₂O is more than or equal to 9 mol percent. In some embodiments, suitable glass compositions further comprise K₂O, MgO and CaO. In a particular embodiment, the glass composition may comprise 61 to 75 mol% SiO₂7-15 mol% Al₂O₃0-12 mol% B₂O₃9-21 mol% Na₂O, 0-4 mol% K₂O, 0-7 mol% MgO and 0-3 mol% CaO.

Another exemplary glass composition comprises: 60-70 mol% SiO₂(ii) a 6-14 mol% Al₂O₃(ii) a 0-15 mol% B₂O₃(ii) a 0-15 mol% Li₂O; 0-20 mol% Na₂O; 0-10 mol% K₂O; 0-8 mol% MgO; 0-10 mol% CaO; 0-5 mol% ZrO₂(ii) a 0-1 mol% SnO₂(ii) a 0-1 mol% CeO₂(ii) a Less than 50ppm of As₂O₃(ii) a And less than 50ppm Sb₂O₃(ii) a Wherein 12 mol percent is less than or equal to (Li)₂O+Na₂O+K₂O) is less than or equal to 20 mol percent, and 0 mol percent is less than or equal to (MgO + CaO) is less than or equal to 10 mol percent.

Another exemplary glass composition comprises: 63.5-66.5 mol% SiO₂(ii) a 8-12 mol% Al₂O₃(ii) a 0-3 mol% B₂O₃(ii) a 0-5 mol% Li₂O; 8-18 mol% Na₂O; 0-5 mol% K₂O; 1-7 mol% MgO; 0-2.5 mol% CaO; 0-3 mol% ZrO₂(ii) a 0.05-0.25 mol% SnO₂(ii) a 0.05-0.5 mol% CeO₂(ii) a Less than 50ppm of As₂O₃(ii) a And less than 50ppm Sb₂O₃(ii) a Wherein 14 mol percent is less than or equal to (Li)₂O+Na₂O+K₂O) is less than or equal to 18 mol percent and 2 mol percent is less than or equal to (MgO + Ca)O) is less than or equal to 7 mol percent.

In a particular embodiment, the alkali aluminosilicate glass composition comprises alumina, at least one alkali metal, and in some embodiments greater than 50 mole% SiO₂And in other embodiments at least 58 mol% SiO₂And in other embodiments at least 60 mole% SiO₂Wherein the ratio ((Al)₂O₃+B₂O₃) V. modifier) > 1, wherein in the ratio the components are expressed in mole% and the modifier is an alkali metal oxide. In a specific embodiment, this glass composition comprises: 58-72 mol% SiO₂9-17 mol% Al₂O₃2-12 mol% B₂O₃8-16 mol% Na₂O and 0-4 mol% K₂O, wherein the ratio ((Al)₂O₃+B₂O₃) V. modifier>1。

In another embodiment, a glass article can include an alkali aluminosilicate glass composition comprising: 64-68 mol% SiO₂12-16 mol% Na₂O, 8-12 mol% Al₂O₃0-3 mol% B₂O₃2-5 mol% K₂O, 4-6 mol% MgO, and 0-5 mol% CaO, wherein: SiO is not more than 66 mol percent₂+B₂O₃CaO is less than or equal to 69 mol%; na (Na)₂O+K₂O+B₂O₃+MgO+CaO+SrO>10 mol%; MgO, CaO and SrO are more than or equal to 5 mol% and less than or equal to 8 mol%; (Na)₂O+B₂O₃)-Al₂O₃Less than or equal to 2 mol percent; na is not more than 2 mol percent₂O-Al₂O₃Less than or equal to 6 mol percent; and 4 mol% is less than or equal to (Na)₂O+K₂O)-Al₂O₃Less than or equal to 10 mol percent.

In an alternative embodiment, the glass sheet may comprise an alkali aluminosilicate glass composition comprising: 2 mol% or more of Al₂O₃And/or ZrO₂Or 4 mol% or more of Al₂O₃And/or ZrO₂。

In some embodiments, a composition for a glass article may be dosed with 0-2 mol% of at least one fining agent selected from the group consisting of Na₂SO₄、NaCl、NaF、NaBr、K₂SO₄KCl, KF, KBr and SnO₂。

The glass article can be a monolithic glass sheet or a laminate. According to one or more embodiments of the present disclosure, a laminate refers to opposing glass substrates separated by an interlayer [ e.g., poly (vinyl butyral) (PVB) ]. The glass sheets forming the laminate sections may be strengthened (chemically strengthened, thermally strengthened, and/or mechanically strengthened) as described above. Thus, a laminate according to one or more embodiments includes at least two sheets of glass joined together by an interlayer, wherein a first sheet of glass defines an outer layer and a second sheet of glass defines an inner layer. In vehicle applications (e.g., automotive glazings), the inner layer is exposed to the vehicle or interior of an automobile and the outer layer faces the exterior environment of the automobile. In vehicle applications (e.g., automotive interiors), the inner layer is not exposed and is placed on an underlying support (e.g., display, instrument panel, center console, instrument panel, seat back, seat front, floor, door panel, body pillar, armrest, etc.), while the outer layer is exposed to the vehicle or automotive interior. In construction applications, the inner layer is exposed to the interior of a building, room or furniture and the outer layer faces the exterior environment of the building, room or furniture. In one or more embodiments, the glass sheets in the laminate are bonded together by an interlayer, such as a polymer interlayer selected from the group consisting of: polyvinyl butyral (PVB), Ethylene Vinyl Acetate (EVA), polyvinyl chloride (PVC), ionomers, and Thermoplastic Polyurethane (TPU).

Another aspect of the present disclosure relates to a method of cold forming a complexly curved glass article as described herein. In various embodiments, cold forming involves bending a continuous glass sheet around a preform having a first bending region with a first set of curve segments and a second bending region with a second set of curve segments, wherein the first and second curve segments are independent, non-parallel, and do not intersect.

Non-limiting example techniques for cold forming complexly curved glass articles include:

placing the glass sheet between two complementary preforms, with the adhesive between the glass sheet and one of the two preforms. For example, any of the preforms shown in fig. 1A-1G and 2A-2D can comprise complementary preforms, and the glass sheet between the preforms can be cold-formed by moving the two preforms toward one another with application of force. Such force may be provided using mechanical force, such as a worm gear, hydraulic force, pneumatic force, or other suitable means of providing an appropriate force to cause the glass sheet to take the shape of the mold. The sandwich is pressed together so that the glass sheet takes the shape of a mould formed by the two preforms.

Attaching a thin frame made of metal (e.g. aluminum, steel, etc.) on the periphery of the glass sheet. The frame is given a shape using a bending or twisting instrument, which in turn bends the glass. The shaped glass and its metal frame can be used as a single article in the same manner as the glass articles described herein.

Sliding the glass sheet into a frame with grooves so that the glass slides in to take the desired shape.

The glass sheet is conformed to the shape of the preform using rollers, guide pins or vacuum.

The glass sheet is snapped into a fixture on the preform.

In one or more embodiments, cold forming is performed at a temperature below the glass transition temperature. Exemplary temperatures include room temperature (e.g., about 21 ℃) or slightly elevated temperatures, such as temperatures less than 200 ℃. In one or more embodiments, the temperature during cold forming is less than or equal to any one of the following temperatures: 300. 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 55, 50, 45, 40, 35, 30, 25, or 20 ℃. In one or more embodiments, cold forming is performed at a temperature related to the glass transition temperature of the glass, e.g., at least 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, or 1,000 ℃ below the glass transition temperature.

In one or more embodiments, the at least one bend is formed according to a cold forming process and the at least one bend is formed according to another process (e.g., a hot forming process). In an alternative embodiment, the full bend is formed according to a cold forming process.

In one or more embodiments, two or more bends are formed according to a cold forming process, but each bend is introduced in a successive cold forming process rather than forming two bends at the same time. In other embodiments, all bends are formed simultaneously during the same cold forming process.

According to another aspect of the present disclosure, a vehicle interior component comprises a complexly curved glass article as described herein. An exemplary vehicle includes: motor vehicles, such as motorcycles, automobiles, trucks, buses; rail vehicles, such as trains and trams; watercraft such as ships and boats; aircraft, such as airplanes and helicopters; and a spacecraft. In one or more embodiments, the vehicle is an automobile. The vehicle interior component may also include a glass article on the support surface. Exemplary vehicle interior components include a display, a center console, an instrument panel, a door panel, a body pillar, a floor, an armrest, and an instrument cluster cover. The support surface may include, but is not limited to, fabric, leather, polymer, wood, metal, and combinations thereof. The glass article may have one or more coatings, such as an anti-glare coating, an anti-reflective coating, an oleophobic coating, an anti-scratch coating, or an ink coating. The glass article may have different coatings on opposing surfaces, such as an ink coating on a first surface and an antireflective coating on a second surface.

In accordance with one or more embodiments of the present disclosure, a glazing cluster cover includes a complexly curved glass article as described herein. According to one or more embodiments, an instrument cluster of a vehicle covers various displays and indicators that enable an operator to operate the vehicle. Including a plurality of gauges, non-limiting examples of which include speedometers, odometers, tachometers, oil pressure gauges, fuel gauges, and the like. Further, the instrument cluster of the vehicle may include indicators for system malfunctions and warnings. The instrument cluster provides a centralized and easy-to-view location for the vehicle operator to display all critical system information. As used herein, "instrument cluster cover" includes a cover that covers an instrument cluster and/or a center stack, which may include other components, such as radios, GPS, heater controllers, and the like.

Another aspect of the present disclosure relates to a vehicle comprising a cabin and an interior comprising vehicle interior components comprising the complexly curved glass article described herein.

It is to be understood that the present disclosure also provides at least the following embodiments:

a 1 st embodiment is directed to a glass article comprising a cold-formed, complexly-curved, continuous glass sheet having a first curve in a first portion of the glass sheet defining a first bending region and having a first set of curve segments and a second curve in a second portion of the glass sheet defining a second bending region and having a second set of curve segments, wherein the first curve segments and the second curve segments are independent, non-parallel, and do not intersect.

In the 2 nd embodiment, the 1 st embodiment includes the following features: the first portion of the glass sheet includes a first bending region and the second portion of the glass sheet includes a second bending region.

In the 3 rd embodiment, the 2 nd embodiment includes the following features: the first portion has a plurality of bending regions having a plurality of first portion bending axes, wherein at least two of the first portion bending axes are parallel.

In the 4 th embodiment, the 3 rd embodiment includes the following features: the second portion has a plurality of bending regions having a plurality of second portion bending axes, wherein at least two of the first portion bending axes are parallel.

In the 5 th embodiment, the 4 th embodiment includes the following features: the first portion includes an S-curve.

In the 6 th embodiment, the 5 th embodiment includes the following features: the second portion includes an S-curve.

In the 7 th embodiment, the 6 th embodiment includes the following features: the first curved region and the second curved region are separated by a flat region that does not curve for a distance of at least 10 millimeters.

In an 8 th embodiment, the 1 st embodiment includes the following features: the glass article has a first bending stress magnitude at the first bending region, a second bending stress magnitude at the second bending region, and a flat region stress magnitude, and the flat region stress magnitude differs from the first bending stress magnitude and the second bending stress magnitude by at least 1 MPa.

In a 9 th embodiment, an 8 th embodiment includes the following features: the flat region stress magnitude differs from the first bending stress magnitude and the second bending stress magnitude by at least 10 MPa.

In the 10 th embodiment, the 1 st embodiment includes the following features: the glass sheet has a first surface and a second surface and a thickness defined by the first surface and the second surface, the thickness being in a range of 25 micrometers to 5 millimeters.

In an 11 th embodiment, the 1 st embodiment includes the following features: at least one of the first and second bends has a radius of curvature greater than 25 mm and less than 5 m.

In a 12 th embodiment, an 11 th embodiment includes the following features: the radii of curvature of the first and second bends are both greater than 25 mm and less than 5 meters.

In a 13 th embodiment, the 1 st embodiment includes the following features: the glass sheet has a first surface and a second surface, wherein a first bending compressive stress at the first surface of the first bend is greater than a first bending compressive stress at the second surface, and wherein a second bending compressive stress at the first surface of the second bend is greater than a second bending compressive stress at the second surface.

In the 14 th embodiment, the 1 st to 13 th embodiments include the following features: the glass article includes a strengthened glass substrate selected from the group consisting of a laminated glass substrate, a chemically strengthened glass substrate, a thermally strengthened glass substrate, and combinations thereof.

In the 15 th embodiment, the 1 st to 14 th embodiments include the following features: the glass sheet comprises an ion-exchangeable alkali aluminosilicate glass composition.

In the 16 th embodiment, the 1 st to 14 th embodiments include the following features: the glass sheet comprises an ion-exchangeable alkali aluminoborosilicate glass composition.

In the 17 th embodiment, the 1 st to 16 th embodiments include the following features: the glass sheet includes a chemically strengthened glass substrate and, in the outer region, is ion exchanged to a depth of layer (DOL) in a range from an outer surface of the glass substrate to about 10 microns to about 90 microns.

In an 18 th embodiment, a 17 th embodiment includes the following features: the outer region has a Compressive Stress (CS) magnitude in a range of 300MPa to 1000 MPa.

In a 19 th embodiment, an 18 th embodiment includes the following features: CS is in the range of 600MPa to about 1000 MPa.

In the 20 th embodiment, the 1 st to 19 th embodiments include the following features: the glass article is selected from the group consisting of an architectural glass substrate, a vehicle interior glass substrate, and an appliance glass substrate.

A 21 st embodiment is directed to a vehicle interior component comprising the glass article of any of the 1 st to 19 th embodiments.

In a 22 nd embodiment, the 21 st embodiment includes the following features: the vehicle interior component has a support surface and a glass article on the support surface.

In a 23 rd embodiment, the 22 nd embodiment includes the following features: the vehicle interior component is selected from the group consisting of a display, a center console, an instrument panel, a door panel, a body pillar, a floor, an armrest, and an instrument cluster cover.

In a 24 th embodiment, a 22 nd embodiment includes the following features: the glass article further includes one or more of an anti-glare coating, an anti-reflective coating, an oleophobic coating, an anti-scratch coating, and an ink coating.

In a 25 th embodiment, the 22 nd embodiment includes the following features: the support surface comprises fabric, leather, polymer, wood, metal, and combinations thereof.

A 26 th embodiment is directed to a vehicle comprising a cabin and an interior, the interior comprising the vehicle interior components of any one of the 20 th to 25 th embodiments.

An 27 th embodiment is directed to an automotive interior component comprising a cold-formed, complexly-curved, continuous glass sheet having a first portion with a first bend defining a first curved region having a first set of curve segments and a second portion with a second bend defining a second curved region having a second set of curve segments, wherein the first and second curve segments are independent, non-parallel and do not intersect, at least one of the first and second portions includes a flat region that does not curve for a distance of at least 10 millimeters, and the glass article has a first bending stress magnitude at the first curved region, a second bending stress magnitude at the second curved region, and a flat region stress magnitude, and the flat region stress magnitude differs from the first bending stress magnitude and the second bending stress magnitude by at least 1 MPa.

A 28 th embodiment is directed to a method of forming a complexly curved glass article, the method comprising cold forming a continuous glass sheet around a preform having a first bending region with a first set of curve segments and a second bending region with a second set of curve segments, wherein the first and second curve segments are independent, non-parallel, and do not intersect.

In a 29 th embodiment, a 28 th embodiment includes the following features: the glass sheet has a glass transition temperature and the cold forming is performed at a temperature below the glass transition temperature.

In the 30 th embodiment, the 29 th embodiment includes the following features: cold forming is carried out at a temperature of less than 200 ℃.

In a 31 st embodiment, a 29 th embodiment includes the following features: the glass sheet prior to being cold formed has a shape that includes a first portion and a second portion that intersect to form a continuous glass sheet.

In a 32 th embodiment, a 31 th embodiment includes the following features: the glass sheet prior to cold forming has a shape selected from the group consisting of an L-shape, a T-shape, an I-shape, a C-shape, an H-shape, a V-shape, and an X-shape.

In a 33 rd embodiment, a 32 nd embodiment includes the following features: cold forming imparts a first bend along a first bend axis in the first portion and a second bend along a second bend axis in the second portion.

In a 34 th embodiment, a 33 rd embodiment includes the following features: cold forming imparts a plurality of bends in the first portion along a plurality of first portion bend axes, wherein at least two of the first portion bend axes are parallel.

In a 35 th embodiment, the 34 th embodiment includes the following features: cold forming imparts a plurality of bends in the second portion along a plurality of second portion bend axes, wherein at least two of the second portion bend axes are parallel.

In a 36 th embodiment, a 35 th embodiment includes the following features: after cold forming, the first portion includes an S-curve.

In a 37 th embodiment, a 36 th embodiment includes the following features: after cold forming, the second portion includes an S-curve.

In a 38 th embodiment, the 33 rd embodiment includes the following features: after cold forming, at least one of the first portion and the second portion includes a flat region that does not bend for a distance of at least 10 millimeters.

In a 39 th embodiment, a 38 th embodiment includes the following features: the glass article has a first bending stress magnitude at the first bending region, a second bending stress magnitude at the second bending region, and a flat region stress magnitude that differs from the first bending stress magnitude and the second bending stress magnitude by at least 1 MPa.

In a 40 th embodiment, the 39 th embodiment includes the following features: the flat region stress magnitude differs from the first bending stress magnitude and the second bending stress magnitude by at least 10 MPa.

In a 41 st embodiment, a 33 rd embodiment includes the following features: the glass sheet has a first surface and a second surface, wherein a first bending compressive stress at the first surface of the first bend is greater than a first bending compressive stress at the second surface, and wherein a second bending compressive stress at the first surface of the second bend is greater than a second bending compressive stress at the second surface.

In a 42 th embodiment, a 28 th embodiment includes the following features: the glass sheet has a first surface and a second surface and a thickness defined by the first surface and the second surface, the thickness being in a range of 25 micrometers to 5 millimeters.

In a 43 rd embodiment, the 28 th embodiment includes the following features: at least one of the first and second bends has a radius of curvature greater than 25 mm and less than 5 m.

In a 44 th embodiment, the 28 th embodiment includes the following features: the radii of curvature of the first and second bends are both greater than 25 mm and less than 5 meters.

In a 45 th embodiment, the 28 th embodiment includes the following features: the glass sheet is coated with a coating prior to cold forming.

In a 46 th embodiment, a 28 th embodiment includes the following features: the coating includes one or more of an anti-glare coating, an anti-reflective coating, an oleophobic coating, an anti-scratch coating, and an ink coating.

In the 47 th embodiment, the 28 th to 46 th embodiments include the following features: the glass article includes a strengthened glass substrate selected from the group consisting of a laminated glass substrate, a chemically strengthened glass substrate, a thermally strengthened glass substrate, and combinations thereof.

In the 48 th embodiment, the 28 th to 47 th embodiments include the following features: the glass sheet comprises an ion-exchangeable alkali aluminosilicate glass composition.

In the 49 th embodiment, the 28 th to 47 th embodiments include the following features: the glass sheet comprises an ion-exchangeable alkali aluminoborosilicate glass composition.

In the 50 th embodiment, the 28 th to 49 th embodiments include the following features: the glass sheet includes a chemically strengthened glass substrate and, in the outer region, is ion exchanged to a depth of layer (DOL) in a range from an outer surface of the glass substrate to about 10 microns to about 90 microns.

In the 51 st embodiment, the 28 th to 46 th embodiments include the following features: the outer region has a Compressive Stress (CS) magnitude in a range of 300MPa to 1000 MPa.

In a 52 th embodiment, a 51 st embodiment includes the following features: CS is in the range of 600MPa to about 1000 MPa.

In a 53 th embodiment, the 28 th to 57 th embodiments include the following features: the glass article is selected from the group consisting of an architectural glass substrate, a vehicle interior glass substrate, and an appliance glass substrate.

Although the disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made in the methods and apparatus of the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.